Modular building construction and erection system utilizing selectively oriented modules

ABSTRACT

This invention relates to a low cost system for erecting multiroom buildings from preformed modules. Precast concrete modular units having opposing side walls and opposing floor and ceiling panels are oriented in relationship to each other so that a side wall of one module closes off selectively, at least partially, an open end of an adjacent module. Fill-in end wall panels are utilized as required to complete a building construction. Additional floor levels stacked on lower levels are employed to provide a building assembly having a predetermined number of floors. Means are provided for integrally connecting together the series of modules defining each floor level. As required, additional connecting means are provided to secure overlying floor levels with floor levels lying therebelow.

United States Patent Klett et al.

[54] MODULAR BUILDING CONSTRUCTION AND ERECTION SYSTEM UTILIZINGSELECTIVELY ORIENTED MODULES [72] Inventors: George G. Klett, Berkeley;Gary L.

Akerstrom, Moraga, both of Calif.

[73] Assignee: Building Block Modules, Inc.,

Richmond, Calif.

[22] Filed: Sept. 14, 1970 [21] Appl. No.: 71,978

[52] US. Cl. ..52/79, 52/236, 52/579, 52/583, 52/587 [51] Int. Cl...E04h 1/04 [58] Field of Search ..52/227-229, 79, 52/234, 236, 583,579-581, 587, 238, 239

[56] References Cited UNITED STATES PATENTS 4 1,024,852 4/1912l-lolmberg ..52/587 1,624,802 4/1927 Rebell ..52/587 2,003,670 6/1935Walker ..52/236 2,373,409 4/ 1945 Myer ..52/227 2,645,114 7/1953Amirikan ..52/587 2,751,635 6/1950 Donnahue ..52/79 3,284,966 11/1966Bolt ..52/79 3,372,519 3/1968 Russell ..52/587 3,377,755 4/1968 Stuckyet al. ..52/236 3,378,971 4/1968 Singer et al ..52/236 3,432,978 3/1969Erickson ..52/227 3,500,595 3/1970 Bennett ..52/228 [451 Nov. 21, 1972Shelley ..52/79 Primary Examiner-Frank L. Abbott AssistantExaminer-Leslie A. Braun Attorney-Flehr, l-lohbach, Test, Albritton &Herbert [57] ABSTRACT This invention relates to a low cost system forerecting multi-room buildings from preformed modules. Precast concretemodular units having opposing side walls and opposing floor and ceilingpanels are oriented in relationship to each other so that a side wall ofone module closes off selectively, at least partially, an open end of anadjacent module. Fill-in end wall panels are utilized as required tocomplete a building construction. Additional floor levels stacked onlower levels are employed to provide a building assembly having apredetermined number of floors. Means are provided for integrallyconnecting together the series of modules defining each floor level. Asrequired, additional connecting means are provided to secure overlyingfloor levels with floor levels lying therebelow.

14 Claims, 15 Drawing Figures PKTENTEDnuvz: m2

SHEET 3 [IF 6 Awewraz: 6:024! 6.

MODULARBUILDING CONSTRUCTION; AND ERECTION SYSTEM UTILIZING SELECTIVELYORIENTED MODULES CROSS-REFERENCE TO RELATED APPLICATION Assigneescopending application Ser. No. 872,608 filed Oct. 30, 1969, entitled.Modular Building, and System for Erecting the Same relates to a modularbuilding construction and erection system utilizing,

precast modules arranged generally incheckerboard fashion so that openareas or spaces are provided between adjacent modules, such spaces beingclosedoff by fill-in wall and ceiling panels, or by other modules,stacked onan underlying series of. modules in preselected fashion tocomplete a building assembly. The present invention is distinguishedfrom the invention of the copending application in. that in the presentbuilding construction and erection system the free space or checkerboardstacking concept of the identified application is not utilized.

BACKGROUND OF THE INVENTION -more floor levels therein. In suchbuildings which include more than one floor level, modules ofupper floorlevels are stacked directly upon and generally inv conformance with theorientation of the modules em.- ployed in floor levels lyingtherebeneath.

Still more particularly, this invention relates to the field of precastconcrete modular building systems which are specifically designed sothat, to the fullest extent possible, all work on individual room unitsdefined by. the respective modules may be effected at a factoryprior to.transportation of the modules to a building site so that only a minimumamount of on-site labor is required in the erection procedures andfinishing procedures to prepare the building for occupancy.

2. Description of the Prior Art While preformed modular buildingconstructions and erection procedures have been generally known andutilized heretofore, so far as is known, the particular construction ofthe modular building construction and erection system employed toprovide the building assembly of the present invention have been unknownheretofore. While as noted above, assignees copending applicationdiscloses an improved and effective modular building construction anderection system in which precast modules are arranged and stacked oneupon the other in checkerboard fashion, utilizing fill-in end wall andfloor and ceiling panels as required to complete a building assembly,such checkerboard arrangement does not employ or suggest the particularmodular building construction and erection system and proceduredisclosed herein.

Specifically, the present invention is designed as a modification of thecheckerboard erection system of said copending. application'and thepresent building construction and system have certain distinctadvantages. and featureswhich make the same utilizable under conditionsoccasionally more suitable for use than the erection system of saidcopending application.

In that regard, an important characteristic of the present inventionwhich distinguishes the same from the improved system. of said copendingapplication, and also from prior systems known in the modular buildingfield, residesin the fact that the present building construction anderection system results from utilization 'of precast modules which: arepositioned in such a fashion thata wall ofionc modulecooperates todefine a full or partial wall of another adjacent module, therebylimitingthe number of fill-in wall panels or floor and ceiling panelsrequired to effect erection of a completed modular building.construction. In the present invention, in distinction to the inventionof said copending application andv contrary to other known procedures inthe prior art, the preformed modules of this invention are arranged in asimplified. fashion which eliminates free. space therebetween' and whichminimizes the total number of separate structural components or partsrequiredtocompletea pluralfloor building assembly.

Furthermore, with a modular building construction of the presentinvention, in which the modular units are preformed at a factory andtheir interiors finished to the fullest possible extent at the factoryprior to transportation tothe construction site, construction costs, canbe greatly reduced. Also, less skilled labor is required at the erectionsite to erect a building construction embodying the present inventionthan to erect buildingsproduced from more conventional constructionprocedures heretofore known.

SUMMARY OF THE INVENTION defined by one or more floor levels, such as amultifamily apartment house or multi-unit office building. Still moreparticularly, this invention relates to a modular building systemutilizing preformed modular units designed to be'oriented relative toand interconnected with each other in a particular fashion so that amultiroom building on one or more levels may be quickly andinexpensively erected with minimum on-site labor.

Furthermore, this invention relates to the manufacture and utilizationof precast building modular units formed at a factory in which theinterior of'each modular unit, such as wall coverings, floor coverings,draperies, internal plumbing walls for kitchens and bathrooms, and thelike may be fully installed at the factory prior to transportation ofindividual modules to the construction site for erection thereat inpreplanned fashion into a multi-room building of predetermined size andpreplanned architectural design. With the present invention, fewerfill-in wall panels and ceiling or floor panels are required than withprior known constructions, thereby minimizing the total number ofstructural components required to complete a building assembly ofpredetermined size and design.

level or on overlying floor levels, into a unitary,stprdy buildingconstruction. More particularly, in that regard, this invention relatesto the inclusion in a building modular unit of improved connectorstructure which is embedded during the module forming procedure into themodule walls at predetermined locations. Such connector structures aredesigned to be selectively interconnected with each other duringerection of a building assembly.

In the aforementioned copending application, a modular buildingconstruction is disclosed which utilizes acheckerboard erection patternwhich obviates the presence of double ceiling and floor panels in amulti-level building. In the present invention such double ceiling andfloor panels are encountered as a result of the stacking procedureinvolved herein. However, this arrangement minimizes the requirement forexterior end wall panels in a completed building construction. That is,with the present invention, the double ceiling and floor constructionemployed is planned to limit the number of fill-in wall, ceiling andfloor panels required to complete a building. Additionally, with thepresent arrangement, double side walls characteristic of prior knownmodular buildings also are obviated. Additionally, with the presentinvention the number of interior fill-in wall panels may besubstantially decreased.

This invention lends itself to a wide variety of uses and buildingconstructions and, by suitable preparation of the casting form in whichthe modular building units preferably are produced from concrete, a widevariety of arrangements for internal and external openings for doors andwindows in the erected building may be effected in accordance with apredetermined building design plan.

The stacking arrangement of the present invention when a multi-floorlevel building is produced generally makes utilization of verticalconnecting means to interconnect overlying and underlying floor levelsoptional. Although such connecting means may be utilized as describedherein, it has been found that the same are not required under allcircumstances, primarily because of the effective means forinterconnecting adjacent modules in each floor level of the buildingbeing erected.

In the present invention, in contrast to that of said copendingapplication, the preformed modular units, comprising opposed side wallsand opposed floor and ceiling panels which define open ends, arearranged on a foundation or on an underlying floor level so that theopen end of one modular unit is closed off to the extent desired by aside wall panel of an adjacent modular unit. As a result, fill-in wallpanels are required generally only at the'outer margins of a buildingconstruction being erected.

From the foregoing, it should be understood that objects of thisinvention include the provision of a low cost, improved modular buildingconstruction and building system; the provision of an improved process,

procedure and system for erecting a modular building facilitateinterconnection thereof with other building units; the provision in abuilding module or improved connector structure designed to facilitateremoval of a precast concrete module from the casting forrnand tosubsequently facilitate erection of a building utilizing such a'module;the provision of improved means for securing together modular buildingunits stacked in one or more layers or floor levels; and the provisionof an improved erection procedure and resulting building construction inwhich precast concrete modular units are oriented relativeto each otherso that the walls of certain units close off the normally open ends ofother units whereby the number of fill-in wall panels required isminimized.

These and other objects of this invention will become apparent from astudy of the following disclosure in which reference is directed to theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an isometric, generallyschematic view illustrating the subject building system and erectionprocedure employed therewith.

FIG. 2 is an isometric, generally schematic view of the subject systemshowing a modified embodiment thereof.

FIG. 3 is a horizontal sectional view through a portion of the buildingsystem of FIG. 1 showing theattachment means to a foundation therefor.

FIGS. 4 through 7 are isometric views of foundation attachment connectorplates effectively utilized in the present building system.

FIG. 8 is a vertical sectional'view through two vertically stackedseries of modular units showing the operative interconnectiontherebetween and the positioning thereof on a foundation therefor.

FIG. 9 is a plan view taken in the plane of line 99 of FIG. 8illustrating details of means for connecting together four modular unitsemploying the improved connecting structure of this invention. I

FIG. 10 is an isometric view of an improved connecting structureutilized herein.

v, FIG. 11 is an isometric view of a connector fitting utilized in thesubject module means.

FIG. 12 is an isometric view of a guide tab utilized in the subjectconnecting means to facilitate stacking of modules one upon the other.

FIG. 13 is a plan view illustrating the interconnection between threecontacting modules.

FIG. 14 is a sectional view taken generally in the plane of line 14-14of FIG. 13 and illustrating the interconnection between overlyingmodules.

} FIG. 15 is a plan view corresponding generally to FIG. 13 and showingthe interconnection of an end wall fill-in panel with a modular unit.

DESCRIPTION OF THE PREFERRED EMBODIMENT Before describing specificdetails of the subject building construction and the erection systemtherefor, and the individual modular units which are employed inerecting a multi-room building construction of one or more floor levels,a brief description will be given of the manufacturing proceduresemployed to produce a modular unit designed for utilization in thepresent system.

Individual modules are cast vertically in a form having opposed sectionswhich are movable toward and away from each other to permit separationof a completed concrete module therefrom. Such form .also permitspositioning of reenforcing rods, electrical conduits, openings forplumbing fixtures, inserts for connecting a completed unit with anadjacent unit in a building construction, inserts for picking up andtransporting a completed unit, and other fixtures, prior to casting.When all such rods, inserts and fixtures are properly positioned, thecasting form is closed and held securely together while concrete orother suitable construction material is pumped into the form and allowedto harden therein.

The basic modular unit in its preferred embodiment consists of anintegral four sided body open at its opposite ends. One preferredembodiment is formed from precast reenforced concrete having exemplaryoutside dimensions of 12 feet by 8 feet 8 inches by 12 feet 8 inches,with 4-inch thick side walls and ceiling and floor panels. Obviously thedimensions of the module can be modified to meet particular constructionneeds as can the panel thicknesses thereof. However, the basic modulesize just described has been found effective for rapidly erecting amodular building construction of the type illustrated in the attacheddrawings. When special modular sizes are desired to provide a modifiedconstruction, preferably the modified modules are increased or reducedin dimensional increments of length, such as increments of 2 feet.

In line with a predetermined plan, the walls of the modules may beformed with suitable window and internal or external door openingsduring casting of the same. Such window and door openings can be blockedout up to sizes of about eight feet to meet particular needs.

By way of further illustration, a concrete module, without door orwindow openings, having the dimensions and wall thickness notedpreviously weighs approximately ten to twelve tons depending upon thetype of concrete utilized.

As is the case with the modular units of the aforementioned copendingapplication, the present building system is designed for mass productionat a factory with completed modules being intended to be prefinished tothe fullest possible extent at the factory for subsequent transportationto the construction site. In that regard, the factory prefinishingoperations may be carried out at various stations for installing orcompleting interior partitions and closets; bathroom and kitchen unitswhich require only plumbing and electrical connections to be completedat the construction site; heating, plumbing and electrical conduits andequipment; doors, windows and trim therefor; painting and finishing;carpets and draperies; and protective wrapping of finished modules fortransportation to the construction site.

As will be described hereinafter, each module is constructed tofacilitate positioning of the same on afoundation or on acorrespondingly oriented underlying module if a multi-level buildingconstruction is desired. In that connection, a particular erectionprocedure has been designed which utilizes to the fullest extent theexisting wall structures of each preformed module so that minimumfill-in wall panel requirements are involved.

With the foregoing in mind, reference is directed to FIG. 1 whichillustrates basic details of this invention and the building systemembodied therein. Preferably, all precast modular units are basicallythe same although, as noted previously, individual units may be providedwith selective window or door openings to fit into the architecturalscheme and design for a particular preplanned building. So far as thisdisclosure is concern'ed, modules employedin the illustrated buildingconstruction or assembly, generally designated 1, are shown essentiallyin the form in which they are produced in the casting procedure notedpreviously (but without internal finishing details illustrated therein).

In that regard, the building construction shown in FIG. 1 is illustratedin the partially completed condition. A series of modules and end wallfill-in panels are shown oriented relative to each other to define abuilding assembly which includes two floor levels designated 2 and 3respectively. It should be understood, of course, that additional floorlevels may be stacked on top of the two floor levels partiallyillustrated if desired in accordance with a particular architecturalplan.

In basic construction each module shown, identified by reference numeral4, comprises a unit which is four sided and generally rectangular incross section defined by two opposed side walls 6 and 7 and integralfloor and ceiling panels 8 and 9 which extend between and connect theside walls. Opposite ends of the unit are generally open andunrestricted as seen. In accordance with predetermined architecturaldesigns, the side walls of certain units may include window openings 13and interior or exterior door openings 14, the latter providing accessbetween adjacent rooms in a completed building when such a door openingis interposed between adjacent modules.

The side walls and ceiling and floor panels are essentially planar andform therebetween upper and lower right angled corner portions. As willbe described hereinafter, the comer portions have embedded therein atselective predetermined locations means for interconnecting modulestogether in a completed building construction.

An important concept of the present invention, and a basic distinctionthereof from the building construction of the copending applicationmentioned above, is that the present building is erected from moduleswithout leaving free spaces between adjacent modules. That is, as seenin FIG. 1, each level of the building is defined by a series of modulesgenerally oriented so that the open end of one module is closed off by aside wall of another module. To that end, in line with a predeterminedarchitectural plan, the modules are positioned in sequence so that theaxis running between the opposite open ends of each module is orientedat generally right angles relative to the open end axis of the adjacentmodule. This angular orientation of adjacent modules produces maximumutilization of side wall panels to minimize the need for fill-ininterior and exterior wall panels.

While with the arrangement shown double thickness ceiling and floorpanels result from the direct stacked relationship of one level of unitsrelative to another, the

minimization of fill-in floor, ceiling and wall panels compensates forthe double floor and ceiling thickness and results, under certaincircumstances, in cost savings at the erection job site.

In that connection, it will be noted also from FIG. 1 that the only needfor fill-in panels arises at the lateral margins of the building. Suchfill-in wall panels may be dimensioned to fit flush with the outermarginal edge of a modular unit, as noted by panel 11 in FIG. 1, oralternatively the peripheral dimensions of such a fill-in wall panel 12may be such that the same may be received within the confines of theside walls and floor and ceiling panels of a module also as seen inFIG. 1. The fillin wall panels may have window or door openings.provided therein as required.

With a flush type wall panel 11 of the type seen in FIG. 1, the same maybe secured in place with conventional fasteners extending through thewall panels into the end margin of the adjacent module or the improvedconnector means of this invention may be utilized in conjunctiontherewith as will be described. With an interiorly positioned fill-inwall panel 12 of the type shown in FIG. 1, conventional fasteners may beextended through the side wall panels 6 and 7 of the module, and alsothrough the ceiling panel 9 thereof, into the edge of the wall panel tohold the same in place in known fashion.

Obviously, caulking or other leak proofing procedures may be employedwith respect to positioning the fill-in wall panels in place or in theformation of any other joints or connections disclosed herein, as may berequired.

Also, referring to FIG. 2, while it is preferred to utilize essentiallythe same dimension modular units in the building construction of thisinvention to simplify erection procedures, to provide improvedappearances and meet aesthetic design considerations, somewhat largermodules, such as the one shown at 4' in FIG. 2, may be-utilized. In thatregard, module 4' is formed with longer side walls 6 and 7' and floorand ceiling panels 8and 9 relative to a shorter module 4 underlying thesame so that an overhanging effect is provided to impart architecturalinterest in the resulting building. Alternatively, the size of anoverlying or underlying module may be reduced in dimension relative tothe module stacked thereon or positioned therebeneath for the samepurpose. In that regard, as will be described, when such oversized orundersized modules are used, selective positioning of the connectingmeans employed is necessary to connect the same with adjacent modules inaccordance with the modified architectural lan. p The module connectingmeans to be described hereinafter has been designed so that it may beutilized in conjunction with securing together two or more modules in agiven floor level. To that end, as illustrated by reference numeral 16in FIG. 1, such connecting means may be employed to secure together fouradjacent modules. Also, as indicated by reference numeral 17, suchconnecting means may be employed to connect three adjacently positionedmodules. Similarly, the connecting means may be employed to securetogether one module and a flush positioned fillin wall panel asindicated by reference numeral 18. Reference numeral 19 in FIG. 1identifies a fill-in panel joint employing conventional fastening meansas mentioned previously. Also, as indicated by reference numeral 21, theimproved connecting means of this invention may be utilized to securetogether two adjacent inline modules as noted.

The respective modules may be positioned and placed in their prearrangedorientation by means of large fork-lift trucks, cranes or the like. Theparticular erection equipment and machinery chosen will be determinedlargely by the size of the building complex being erected. Whileavailable equipment may be employed, specially designed equipment foruse in erecting the present system may be preferred under certaincircumstances.

While hereinafter reference will be directed to means for horizontallyconnecting a series of adjacent modules in the same floor level togetherinto a unitary assembly, it is also contemplated that under certainzoning ordinances and building code conditions it may be necessary ordesirable to operatively vertically interconnect overlying floor levelsof a building with those underlying the same and to tie all the floorlevels to a supporting foundation. If such requirement is encountered,suitable securing means, such as the post tensioning arrangementillustrated and described in the aforementioned copending application,may be utilized herewith. If such post tensioning, or other suitablemeans for vertically interconnecting overlying modules with underlyingmodules, is employed, the accommodation therefor may be made in thecasting form during production of the particular modules in line with apredetermined architectural plan. Because post tensioning, and otherequivalent vertical connecting systems, are not per se novel and havebeen utilized heretofore, a disclosure thereof has not been made indetail herein.

It has been found, that under many circumstances verticalinterconnection of the respective floor levels of a building embodyingthe present system is not required, it being normally adequate, becauseof the substantial weight of the precast modules, to securelyinterconnect together adjacent modules in the same floor level. Eachlevel of the building forms a unitary assembly which, under manycircumstances, is strong and rigid enough to withstand stresses to whicha building is exposed without requiring additional vertical connectionto other structures or levels.

While it is generally contemplated that adjacent modules will beoriented with their open ended axes arranged relative to each other, ifit is desired to produce an enlarged internal room dimension, two ormore modules may be arranged with their open ends axially aligned asshown by the two modules lying at the left of the building in FIG. 1. Byusing modules of less than standard length, such as half-length orquarter length, enlarged rooms at the outer margin of a building may beproduced as desired. Generally, however, adjacent'modules are orientedas noted previously in line with the basic concept of this invention.

Referring to FIG. 3, one preferred means for connecting the subjectbuilding construction to a supporting foundation is illustrated. Suchmeans comprises a series of securing plates designated 27, 28, 29 and 31respectively, each of which is formed to insure secure interconnectionof adjacent modules of the first level of a building to a supportingfoundation. In that regard, it will be seen that each of the securingplates has one or more upwardly projecting tabs 36 thereon whichincludes a tapered, angularly oriented bent point 37 projecting in apredetermined direction therefrom. Also, each tab has two or more holes38 provided therethrough by means of which the respective plates may besecured to a supporting foundation for the building.

The tabs 36 provide guide means which facilitate proper positioning ofmodules upon the foundation. Such tabs are designed to cooperate withand be received in connecting means positioned at the corners of therespective modules or fill-in wall panels during erection of thebuilding as will be described.

FIG. 3, it will be noted, illustrates a portion of the first level floorplan of the building of FIG. 1. In that regard, it will be seen thatsuch figure shows both the principal feature of orienting adjacentmodules at 90 relative to each other, and the alternative feature oforienting two adjacent modules in axial alignment with each other.

The securing plate 27 shown in FIG. 4 is employed to operativelyinterconnect four modules in a joint as identified by reference numeral16. Similarly, the respective plates 28 and 29 shown in FIGS. Sand 6 aredesigned to interconnect three and two modules, respectively, as shownby reference numerals 17' and 21 in FIG. 3. Finally securing plate 31shown in FIG. 7 is used to properly position a fill-in flush wall panel11 to close off the end of a module as shown by reference numeral 18. Itwill be understood that the guide tabs 36 on the respective securingplates are oriented in accordance with the particular type of modulejoint of which the associated securing plate forms a part.

While the securing plates shown in FIGS. 4 through 7 are exemplary ofthe type of foundation connection means suitably employed in thisinvention it should be understood that modifications thereof to meetparticular needs also may be utilized as required.

Taking FIG. 3 in conjunction with FIG. 8, it will be 'noted that thebuilding construction is intended to be supported upon a foundation,such as a poured concrete slab or spaced piers, generally designated 41,which is designed to rigidly support each of Y the modulesat its cornersand also at selected locations between the corners as may be required inline with accepted engineering practice.

Mounting bolts, generally designated 43, are cast in place when thefoundation slab 41 is poured. The threaded upper ends of the bolts 43project from the foundation upper surface and are used to secure therespective mounting plates in place as seen in FIG. 8. To that end, eachbolt has a leveling nut 44 threadedly secured thereon beneath anassociated mounting plate. When the respective leveling nuts areproperly oriented, the mounting plates are positioned thereon andsecured thereto by hold down nuts 47 engaged with the upper surface ofthe respectivemounting plates. Thereafter, the space between thefoundation slab and the mounting plate is filled with grouting toprovide a footing 48. When thus arranged, each mounting plate has itsupwardly projecting tabs properly oriented to perform their function ofguiding and positioning each of the respective modular units 4 intoplace in conjunction with the foundation and the mounting plates securedthereto.

Each of the modular units is provided at its upper and lower marginswith the aforementioned connecting means defined by a specially designedconnecting box structure which is cast in place when the module is made.Each such connecting box structure is designated 51 and, with theexception of the special module configuration and location shown at 51in FIG. 2, eachsuchconnecting box structure is located closely adjacentthe corner of the respective ceiling and wall panels of a givenmodularunit.

In its preferred embodiment, each connecting box structure 51 includesas an important component thereof a separate guide tab 52 (FIG. 12)having a tapered angularly oriented bent point 53 integral therewith.The base of the tab is provided with a hole 54 therethroughto permitattachment of the tab as part of a connecting box structure in thoselocations where such a tab is desirably provided to facilitate operativeinterconnection of vertically stacked building modules in the mannerbest seen in FIG. 8.

As shown in FIG. 10, each connecting box structure comprises an openended connector box 56 which is generally rectangular in cross sectionand is defined by opposed pairs of integral side walls. The box 56 maybe forrnedfrom any suitable procedure, such as by cutting a metalextrusion to the desired length, or by folding a flat metal strap intothe shape illustrated and welding the same together.

Structure for rigidly bonding the connector box 56 within the ceiling orfloor panel of a building module is integrally connected to the boxstructure, preferably by welding. Such bonding structure comprises afirst reenforcing member 57 defined by a bent length of conventionalconstructional reenforcing rod having spaced leg portions as shown, eachof which includes a bent marginal end portion 58 andan integralintermediate arcuately curved portion 59, the latter being positionedgenerally within the confines of the connector box 56. The arcuateportion 59 defines a hook member by means of which a connector box andthe module in which the same is embedded may be lifted or otherwisemoved during manufacture of a module or during positioning of the moduleduring, erection of a building assembly.

A second reenforcing member, defined by another length of bentreenforcing rod 61 including a curved arcuate intermediate portion 62and marginal end portions 63 integral with the spaced legs thereof, isattached by welding the same to an outer surface of the connector box.

An additional anchoring member, defined by a rigid generally flat metalstrap 64, is welded at one of its ends to the surface of the connectorbox adjacent the arcuate portion 62 of the rod 61. Strap 64 extends atan angle relative to the connector box of approximately 45. The end ofthe strap is bent generally at right angles thereto to define an endmargin 66 which assists in anchoring the strap securely in place in thebuilding module.

While bent dual reenforcing rod structures 57 and 61 are preferred ascomponents of the module connecting means, it should be understood that,under certain circumstances, the same may be replaced by flat strapssimilar to that defined by strap 64 or by single rods of suitablestrength.

It should further be understood that the reenforcing rod structures 57and 61 are interfitted with the conventional reenforcing rods embeddedin the ceiling and the connector box 56 is integrally and rigidly tiedin with the basic structure of the modular unit. The rod.

structures 57 and 61 extend in the direction of the planes of both aside wall and a floor or ceiling panel of the modular unit. The bentends 58 and 63 of the reenforcing rod structures and 66 of thereenforcing strap 64 insure secure interconnection of a connector boxwith the modular unit. a

In that regard, it should be understood that one such connecting boxstructure preferably is located adjacent each of the corners of amodular unit, with four such connecting box structures being oriented ineach of the floor and ceiling panels thereof. Thus, the connecting boxstructures are available to facilitate removal of a modular unit from acasting form and alsoto assist in positioning of a module duringbuilding erection. Posi tioning of the connecting box structure in agiven module is best seen from FIGS. 8 and 9.

g It should be understood that the guide tabs 52 mentioned previouslyare positioned in predetermined connecting box structures after properorientation of a modular unit has been effected. Such tabs are providedonly in conjunction with those connecting box structures which areembedded in the ceiling panel of a given unit so as to be available toassist in properly positioning another modular unit to be stackedthereon in the manner shown in FIG. 8. Because the respective connectingbox structures in the ceiling panel of a given module are accessibleprior to stacking of another module thereon, adjacent modules to behorizontally interconnected may be so connected and the positioning tabs52 may be properly located prior to such stacking.

While the connecting box structure shown in FIG, 10 is suitable for mostpurposes, it should be understood that to meet special needs, such aswhen a connector box 56 to be provided in a fill-in panel 11 or 12, theanchoring strap 64 and the bent ends 63 of the reenforcing rod structure61 may be eliminated because of the generally planar construction ofsuch afill-in wall panel. Also for specific purposes, other alterationsto the connecting box structure may be made to meet particular needs butin general the structure as shown in FIG. 10 is utilized at therespective corners of the building modules in the manner seen in FIGS.8, 9 and 13 through 15.

A fitting for horizontally interconnecting adjacent modules at theirupper corners is employed as part of the module connecting means. Suchfitting 71 may take the form shown in FIG. 11 and comprises an openended body 72 which is generally square in cross section defined byopposed walls. The fitting body may be cut from a metal extrusion or maybe formed from a flat metal strap bent and welded into a unitary body.Each of the opposite walls of the fitting is provided with a centrallylocated hole 73 for the purpose to be described. I I

As best seen in FIGS.. 8 and 9, when four modular units are properlyoriented to be interconnected, the corner portions thereof are slightlyoffset or staggered relative to each other to define a generallyrectangular vertically extending space 74 therebetween in which afitting 71 is receivable. Such staggered orientation results from thefact that the respective modules, when axially oriented 90 relative toeach other, are approximately 8 inches'longer in one direction than theother, hereby creating a 4-inch open space between adjacent modules whenlocated as shown. In that regard, such vertical space may be left opento receive therein electrical conduits, plumbing pipes or the like, orthe same may be filled with insulation or grouting applied after themodules are in place but before adjacent modules are horizontallyinterconnected in the manner shown.

Each of the connector boxes 56 is provided with an aperture 75 in itsend wall through which a bolt and nut fastener 76 may be extended whenthe fitting 71 is properly oriented relative to the respective connectorboxes with the apertures 73 and 75 of the respective members aligned toreceive the bolt and nut fasteners therethrough as seen in FIG. 8. Itshould be understood that the bolt and nut fasteners, in addition tosecuring together all four modules throughfitting 71, also hold theguide tabs 52 in place in the manner also illustrated in FIG. 8. g

It has been found preferably to attach by welding or the like areenforcing shim 78 within the respective connector boxes 56 in themanner seen in FIGS. 8 and 10 to reenforce the end of connector box andto provide suitable spacing for the guide tabs relative to a connectorbox of a module to be stacked thereon. A similar shim 79 preferably ispositioned between the end of each connector box 56 and the adjacentwall of the fitting 71 to further provide proper positioning of modulesbeing stacked on underlying modules in a building assembly.

It will be understood from FIG. 8 that the guide tabs 52 insure properpositioning of underlying and overlying modules, just as guide tabs 36insure proper positioning of overlying modules and underlying foundationsecuring plates. In that connection, it should be understood thatnormally no physical interconnection is I required at the floor panelsof the respective modules, the weight of the respective modules beingnormally sufficient to maintain the same securely in place, with theguide tabs precluding lateral shifting thereof. The physicalinteiconnection of stacked modules normally is made only at the ceilingcomers of the modules through the fasteners 76 and fittings as shown inFIG. 9.

As shown in FIG. 14, the connecting effect of the guide tabs in eachmodule joint is clearly illustrated between underlying and overlyingmodules. Such interconnection insures a secure joint between underlyingand overlying modules with the substantial weight of the overlyingmodules maintaining the same effectively in place on the underlyingmodules. I

As noted from FIGS. 13 and 15, when less than four modules are to behorizontally interconnected, the fitting '11 may be eliminated and theconnector boxes may be directly secured to each other by fasteners 76.In FIGS. 13 and 14, a joint is shown between three modules broughttogether in the manner illustrated by reference numeral 17 in FIG. 3.Similarly, FIG. 15 shows a joint between an end wall fill-in panel 11and a module in the manner illustrated by reference numeral 18 in FIG.3. In that latter regard, each connector box 56 preferably is providedwith a second bolt receiving hole 80 in an outer side wall thereof asbest seen in FIGS. and 15, to receive a fastener 76 therethrough when ajoint of the type seen in FIG. is required. In

that same connection, it will be noted from FIG. 15 that the connectingbox structure 51 positioned in the end wall fill-in panel 11 has theaforementioned anchoring strap 64 and the second reenforcing rodstructure 61 omitted therefrom because the end wall panel cannotaccommodate the same therein because of its generally planarconfiguration.

Thus, it will be understood referring to FIGS. 9 and 13 through 15 thateach connecting box structure of the present invention may beeffectively utilized to insure secure interconnection between adjacentupper and lower modular structures to meet almost any particular need.Normally such connecting box structures are embedded closely adjacentthe respective corners of the modules but under certain architecturalcircumstances the same must be embedded at a special location as seen at51' in FIG. 2 to meet a particular need.

Having thus made a full disclosure of a preferred embodiment of themodular building system of this invention, reference is directed to theappended claims which define the scope of protection to be afforded tothis invention.

We claim:

1. A modular building construction intended for human habitationcomprising A. a series of substantially identical four sided one pieceprecast and preformed concrete building modules each of which comprisesa room unit of a size sufficient to permit adult humans to move freelythereabout therein, each such module being defined by l. a pair ofopposed side walls, and 2. a pair of opposed floor and ceiling panelsintegral with and formed as one piece with said side walls,

3. said floor and ceiling panels being integrally connected with saidside walls at opposed upper and lower generally right angled cornerportions of such module,

4. opposite ends of such module being generally open and unrestrictedprior to assembly thereof with other modules of said series into saidbuilding construction,

5. each of such module opposite ends being defined by a series of fourgenerally smooth edge portions of said panels and side walls which liegenerally in a single plane so that each of such module ends may beabutted against another module of said series,

. the outer surfaces of the panels and walls which define each of saidcorner portions of such module being generally smooth so that each comerportion of such module may be positioned in contacting abuttingengagement with another module of said series,

. the maximum dimensions and configuration of that portion of each ofsaid side walls of such module which lies between the inner surfaces ofsaid floor and ceiling panels corresponding 6 generally to the internaldimensions and configuration of the respective open ends of such module,

B. the majority of adjacent alternate modules of said series beingoriented generally a right angles relative to each other with the endedges of the floor and ceiling panels of one module generally contactingand abutting upper and lower comer portions of aside wall of anothermodule,

1. said side wall of each said other module closing off substantiallycompletely said open end of each said one module in accordance with thepredetermined architectural plan for said building construction,

C. foundation structure initially separate from said series of modulesupon which the respective modules of said series are supported,

D. securing means including guide and positioning structure interposedbetween said foundation structure and the respective modules of saidseries for securely interconnecting said modules with said foundationstructure, and

E. releasable connecting means for separably securing said series ofmodules together horizontally into an operative building assembly,

1. said connecting means being positioned at generally abutting uppercomer portions of said adjacent modules,

. each group of four abutting modules of said series having theirrespective generally abutting comer portions offset relative to eachother to define a generally rectangular vertically extending openingtherebetween,

3. and a connector fitting positioned in said opening in alignment withsaid releasable connecting means of said group of modules providingstructure by means of which said group of modules is releasably yetsecurely connected therewith and with each other.

2. The building construction of claim 1 which further includes F. asecond series of said building modules corresponding to said firstmentioned series of modules and being arranged generally as recited inclaim 1 and positioned to overlie the modules of said first mentionedseries to define thereabove a second floor level of said building, and

G. other releasable connecting means for separably securing said secondseries of modules together horizontally to define said second floorlevel,

1. said other connecting means being positioned at generally abuttingcorner portions of said adjacent modules of said second series ofmodules.

3. The building construction of claim 2 which further includes H.further connecting means for vertically joining together said first andsecond series of said modules to each other and to said foundationstructure provided for said building.

4. The building construction of claim 2 in which the modules of saidsecond series of modules are positioned on and supported directly by theside walls and ceiling panels of correspondingly oriented modules ofsaid first series of modules.

5. The building construction of claim 1 in which at least one side wallof preselected modules is provided with an opening therethrough t0define an access opening therein, such as for a door and window.

6. The building construction of claim 1 which further includes F. endwall fill-in panels positioned to close off said open ends of thosemodules which define outer margins of said building construction, and G.means for securing each of such fill-in panels in place at the end ofits associated module. 7. The building construction of claim 1 in whichsaid connecting means comprises l. a hollow connector box embedded ineach ceiling panel of each module of said series adjacent a panelthereof, whereby each connector box in a floor panel of one module isengageable with a connector box of another module overlying the same.10. The building construction of claim 9 in which said connecting meansfurther includes 3. reenforcing structure projecting in at least onedirection from each connector box and secured thereto to insureeffective embedding of such connector box in its associated module.

11. The building construction of claim 10 in which such reenforcingstructure projects in three directions from each connector box into thetwo panels of an as sociated module which define a corner thereof.

12. The building construction of claim 9 which further includes I 3.guide tab means projecting from each connector box embedded in theceiling panels of said series of modules to be received in the connectorboxes embedded in the floor panels of other modules to be stacked onsaid series of modules.

13. The building construction of claim 1 in which the corner portions ofeach group of four modules of said series spaced inwardly from the outermargins of said building construction define a vertical space ofgenerally square configuration therebetween, the dimensions of each suchspace corresponding generally to said thickness of said side walls andceiling and floor panels.

14. The building construction of claim 13 in which a fitting formingpart of said connecting means is received in said space and said spaceis filled with insulating material.

1. A modular building construction intended for human habitationcomprising A. a series of substantially identical four sided one pieceprecast and preformed concrete building modules each of which comprisesa room unit of a size sufficient to permit adult humans to move freelythereabout therein, each such module being defined by
 1. a pair ofopposed side walls, and
 2. a pair of opposed floor and ceiling panelsintegral with and formed as one piece with said side walls,
 3. saidfloor and ceiling panels being integrally connected with said side wallsat opposed upper and lower generally right angled corner portions ofsuch module,
 4. opposite ends of such module being generally open andunrestricted prior to assembly thereof with other modules of said seriesinto said building construction,
 5. each of such module opposite endsbeing defined by a series of four generally smooth edge portions of saidpanels and side walls which lIe generally in a single plane so that eachof such module ends may be abutted against another module of saidseries,
 6. the outer surfaces of the panels and walls which define eachof said corner portions of such module being generally smooth so thateach corner portion of such module may be positioned in contactingabutting engagement with another module of said series,
 7. the maximumdimensions and configuration of that portion of each of said side wallsof such module which lies between the inner surfaces of said floor andceiling panels corresponding generally to the internal dimensions andconfiguration of the respective open ends of such module, B. themajority of adjacent alternate modules of said series being orientedgenerally a right angles relative to each other with the end edges ofthe floor and ceiling panels of one module generally contacting andabutting upper and lower corner portions of a side wall of anothermodule,
 1. said side wall of each said other module closing offsubstantially completely said open end of each said one module inaccordance with the predetermined architectural plan for said buildingconstruction, C. foundation structure initially separate from saidseries of modules upon which the respective modules of said series aresupported, D. securing means including guide and positioning structureinterposed between said foundation structure and the respective modulesof said series for securely interconnecting said modules with saidfoundation structure, and E. releasable connecting means for separablysecuring said series of modules together horizontally into an operativebuilding assembly,
 1. said connecting means being positioned atgenerally abutting upper corner portions of said adjacent modules, 2.each group of four abutting modules of said series having theirrespective generally abutting corner portions offset relative to eachother to define a generally rectangular vertically extending openingtherebetween,
 3. and a connector fitting positioned in said opening inalignment with said releasable connecting means of said group of modulesproviding structure by means of which said group of modules isreleasably yet securely connected therewith and with each other.
 1. Amodular building construction intended for human habitation comprisingA. a series of substantially identical four sided one piece precast andpreformed concrete building modules each of which comprises a room unitof a size sufficient to permit adult humans to move freely thereabouttherein, each such module being defined by
 1. a pair of opposed sidewalls, and
 1. a hollow connector box embedded in each ceiling panel ofeach module of said series adjacent a corner thereof adapted to beintegrally connected with another module of said series.
 1. said otherconnecting means being positioned at generally abutting corner portionsof said adjacent modules of said second series of modules.
 1. saidconnecting means being positioned at generally abutting upper cornerportions of said adjacent modules,
 1. said side wall of each said othermodule closing off substantially completely said open end of each saidone module in accordance with the predetermined architectural plan forsaid building construction, C. foundation structure initially separatefrom said series of modules upon which the respective modules of saidseries are supported, D. securing means including guide and positioningstructure interposed between said foundation structure and therespective modules of said series for securely interconnecting saidmodules with said foundation structure, and E. releasable connectingmeans for separably securing said series of modules togetherhorizontally into an operative building assembly,
 2. each group of fourabutting modules of said series having their respective generallyabutting corner portions offset relative to each other to define agenerally rectangular vertically extending opening therebetween,
 2. Thebuilding construction of claim 1 which further includes F. a secondseries of said building modules corresponding to said first mentionedseries of modules and being arranged generally as recited in claim 1 andpositioned to overlie the modules of said first mentioned series todefine thereabove a second floor level of said building, and G. otherreleasable connecting means for separably securing said second series ofmodules together horizontally to define said second floor level,
 2. apair of opposed floor and ceiling panels integral with and formed as onepiece with said side walls,
 2. another connector box embedded in eachfloor panel of each module of said series adjacent a corner thereof andin alignment with a correspondingly located connector box in the ceilingpanel thereof, whereby each connector box in a floor panel of one moduleis engageable with a connector box of another module overlying the same.3. guide tab means projecting from each connector box embedded in theceiling panels of said series of modules to be received in the connectorboxes embedded in the floor panels of other modules to be stacked onsaid series of modules.
 3. reenforcing structure projecting in at leastone direction from each connector box and secured thereto to insureeffective embedding of such connector box in its associated module. 3.said floor and ceiling panels being integrally connected with said sidewalls at opposed upper and lower generally right angled corner portionsof such module,
 3. and a connector fitting positioned in said opening inalignment with said releasable connecting means of said group of modulesproviding structure by means of which said group of modules isreleasably yet securely connected therewith and with each other.
 3. Thebuilding construction of claim 2 which further includes H. furtherconnecting means for vertically joining together said first and secondseries of said modules to each other and to said foundation structureprovided for said building.
 4. The building construction of claim 2 inwhich the modules of said second series of modules are positioned on andsupported directly by the side walls and ceiling panels ofcorrespondingly oriented modules of said first series of modules. 4.opposite ends of such module being generally open and unrestricted priorto assembly thereof with other modules of said series into said buildingconstruction,
 5. each of such module opposite ends being defined by aseries of four generally smooth edge portions of said panels and sidewalls which lIe generally in a single plane so that each of such moduleends may be abutted against another module of said series,
 5. Thebuilding construction of claim 1 in which at least one side wall ofpreselected modules is provided with an opening therethrough to definean access opening therein, such as for a door and window.
 6. Thebuilding construction of claim 1 which further includes F. end wallfill-in panels positioned to close off said open ends of those moduleswhich define outer margins of said building construction, and G. meansfor securing each of such fill-in panels in place at the end of itsassociated module.
 6. the outer surfaces of the panels and walls whichdefine each of said corner portions of such module being generallysmooth so that each corner portion of such module may be positioned incontacting abutting engagement with another module of said series, 7.The building construction of claim 1 in which said connecting meanscomprises
 7. the maximum dimensions and configuration of that portion ofeach of said side walls of such module which lies between the innersurfaces of said floor and ceiling panels corresponding generally to theinternal dimensions and configuration of the respective open ends ofsuch module, B. the majority of adjacent alternate modules of saidseries being oriented generally a right angles relative to each otherwith the end edges of the floor and ceiling panels of one modulegenerally contacting and abutting upper and lower corner portions of aside wall of another module,
 8. The building construction of claim 7 inwhich a hook member is secured in each such connector box to facilitatepositioning of a module in said building construction.
 9. The buildingconstruction of claim 7 in which said connecting means further comprises10. The building construction of claim 9 in which said connecting meansfurther includes
 11. The building construction of claim 10 in which suchreenforcing structure projects in three directions from each connectorbox into the two panels of an associated module which define a cornerthereof.
 12. The building construction of claim 9 which further includes13. The building construction of claim 1 in which the corner portions ofeach group of four modules of said series spaced inwardly from the outermargins of said building construction define a vertical space ofgenerally square configuration therebetween, the dimensions of each suchspace corresponding generally to said thickness of said side walls andceiling and floor panels.